Catalyst for catalytic cracking or steam reforming of hydrocarbons and process for producing the catalyst

ABSTRACT

A CATALYST FOR CATALYTIC CRACKING OR STEAM REFORMING OF HYDROCARBONS AND THE PROCESS FOR PRODCUCING THE SAME, IN WHICH SAID CATALYST BEING OF ALKALI POLYALUMINATES, OR 2% OR MORE OF ALKALI POLYALUMINATES SUPPORTED ON REFRACTORY CARRIER, OR THE ABOVE-MENTIONED CATALYSTS WHICH ARE ADDED WITH 0.5% OR MORE OF CHROME OR A METAL SELECTED FROM GROUP VIII OF THE PERIODIC TABLE, OR AMIXUTRE THEREOF.

Sept. 26, 1972 GORO YAMAGUCHl ET AL 3,694,379

CATALYST FOR CATALYTIC CRACKING 0R STEAM REFORMING OF HYDROCARBONS AND PROCESS FOR PRODUCING THE CATALYST Filed April 1', 1970 100- [-YJ g a.

"-Al 0 E b 2 3 01A U09 m v 1 m z '73 r 6 m 30 a :2 -=n a N o H 04 Q E 5 COMMERCIALLY AVAILABLE fi CATALYST 0 A DURATION OF REDUCTION (hours) atent Cfice Patented Sept. 26, 1972 Japan Filed Apr. 1, 1970, Ser. No. 24,543 Claims priority, application Japan, Aug. 28, 1969, 44/67,562 Int. Cl. B01j 11/06, 11/40 US. Cl. 252-455 R 8 Claims ABSTRACT OF THE DISCLOSURE A catalyst for catalytic cracking or steam reforming of hydrocarbons and the process for producing the same, in which said catalyst being of alkali polyaluminates, or 2% or more of alkali polyaluminates supported on refractory carrier, or the above-mentioned catalysts which are added with 0.5% or more of chrome or a metal selected from Group VIII of the Periodic Table, or a mixture thereof.

This invention relates to a catalyst composition for catalytic cracking or steam reforming of hydrocarbons, consisting of one member selected from the group of alkali polyaluminates (pi-alumina or R O' l1Al O p'-alumina or R O-78Al O 3"-alu-rnina or R O--6Al O (wherein R is Na or K) or a catalyst being supported on refractory carrier containing at least 2% by weight of an alkali polyaluminate, calculated as an alkali metallic oxide, and it also relates to a process for producing the same. Further, it relates to a catalyst composition for catalytic cracking and steam reforming of hydrocarbons, the catalyst being supported on refractory carrier, characterized in that it is prepared by adding at least 0.5% of chrome or a metal selected from Group VIII of the Periodic Table or a mixture thereof, calculated as an oxide, to one member selected from the group of alkali polyaluminates or other refractory carrier material incorporated with at least 1.0% of an alkali polyaluminate, calculated as an alkali metallic oxide, and it also relates to a process for producing the same.

Generally, when hydrocarbons are subjected to catalyticcracking or steam reforming over catalysts, catalysts will maintain their activity for a short time and allow carbon to deposit easily thereon thereby necessitating repeated regeneration of catalysts by burning out the carbon deposited on the deactivated catalyst. This regeneration process of catalysts not only makes the operation of a reaction furnace complicated but also is time-consuming and ineflicient. If this regeneration is neglected or the operation of the furnace is continued by using insufficiently regenerated catalysts, carbon will be deposited in pores of catalysts, thereby destroying the structure thereof in such a way as to weaken the bond among the constituents thereof, possibly resulting in the collapse of a part or all of constituents.

This is reported to be due to the reaction of aromatic substances, which are intermediate products obtained by the decomposition of hydrocarbons, at the acidic point of the catalysts. In particular, even catalysts, which consists only of nickel and alumina and are free of acidic substances such as Si0 and the like, will be unable to prevent the deposition of carbon thereon if used for a long time, because of the presence of acidic point of Lewis acid, a non proton acid, in the alumina (A1 0 In an attempt to overcome such disadvantages, improvements in catalysts composition have been proposed and practically made, one of the improvements being such as the addition of the chromate or dichromate of an alkali metal or alkali metallic salt such as carbonate to the catalysts to neutralize the acidic point thereof (Japanese Patent Gazette of Publication No. Sho 40-26413). However, the catalysts incorporated with said additive have been proved to have a shorter catalytic life because, when used, they are exposed to high temperatures under a reducing atmosphere whereby the alkali metal present in the additive is gradually volatilized in such a manner that an approximate half of the amount of the alkali metal is lost by volatilization after one-year use of the catalysts.

Various studies were made by the inventors, with the object of allowing the catalysts to contain an alkali metal in an amount enough to keep them neutral and in the nonvolatile form during their use. As a result of the studies, it has been found that the object is satisfactorily achieved by the addition of the polyaluminate of an alkali to the catalysts.

El-A1 0 which is a mineral having the composition of R O-11Al- O (wherein R is Na or K), has been known as one of the conventional alkali polyaluminates; and the existence of two new alkali polyaluminates, these being [3'-alumina and fi"-alumina respectively having the composition of R O-78Al O and R O-56Al O (wherein R is K or Na), which have a higher content of an alkali metal, has been found by Yamaguchi and others who are among the inventors (refer to Bulletin of the Chemical Society of Japan, Vol. 41, No. 1, pp. 93-99 (1968)). The term alkali polyaluminates used herein designates sodium and potassium polyaluminates in which both said conventional and new polyaluminates are included. These minerals will decompose at a low rate even when exposed to a high-temperature reducing atmosphere for a long time, whereby the alkali metal present in the minerals is difiicult to volatilize and consequently hardly decreases in amount.

The accompanying drawing shows the results of a test in which a potassium polyaluminate (fl"Al O containing 12.01% of K 0) and commercially available nickel catalyst incorporated with potassium salt (containing 8.12% of K 0) were heated in the hydrogen flow at a temperature of 1000 C. for 1500 hours in order to study how the potassiums present therein volatilize during heatmg.

It has been found that the alkali present in said alkali polyaluminate is volatilized at a considerably lower rate than the one present in commercially available catalysts. Therefore, such an alkali polyaluminate, when used as a catalyst, will serve to keep the catalyst neutral for a longer time and will be remarkably effective in inhibiting the deposition of calbonaceous substances on the catalyst due to the fact that a portion of the alkali metal moves within the catalyst thereby combining principally with the acidic point of the catalyst.

When hydrocarbons are subjected to catalytic cracking in the presence of steam by using a catalyst containing said alkali polyaluminate or a catalyst prepared by adding at least 2% of an alkali polyaluminate, calcuated as an alkali metallic oxide (Na O or K to other refractory carrier, oxidation reaction, i.e., water gas reaction is especially promoted. Therefore, the amount of carbon to be deposited on the catalyst is very small. Formation of tar is also negligibie. Thus, a gas having a high content of hydrogen (H and consisting of methane (CH ethylene (C H carbon dioxide (CO and a small amount of carbon monoxide (CO) is obtained. This gas decomposes to such an extent where other heavy hydrocarbons are hardly noticed. It has been found that town gas having an ideally high calorific value can be produced in this way at an extremely low cost.

In catalytic cracking of hydrocarbons having 5 to 6 carbon, such as naphtha or the like, the space velocity of liquid should be preferably low, that is, approximately 1, if it is desired to produce town gas. A highly combustible and safe gas having a calorific value of as high as 6000 Kcal./Nm. and containing hydrogen (H methane (CH etc. in a great quantity and being free from carbon monoxide (CO) can be produced at a reaction temperature of 800 C. On the other hand, in producing ethylene (C H the space velocity of liquid should be preferably higher, that is, about 5-10, whereby a gas having a good yield of ethylene can be produced.

Another important characteristic of this catalyst is that it has the quite same effect as stated above in catalytically cracking heavy hydrocarbons of crude oil and the like thereby producing a gas having a calorific value of as high as 6000-7000 KcaL/Nm. and being free of hydrocarbons above propylene.

Steam reforming reaction of hydrocarbons is remarkably promoted by adding at least 0.5% of chrome oxide and a metallic oxide of Group VIII of the periodic table to a catalyst containing an alkali polyaluminate or a catalyst prepared by incorporating at least 1.0% of alkali polyaluminate, calculated as an alkali metallic oxide (Na O or K 0), to other refractory carrier material. A gas that has reached equilibrium is produced at a temperature of about 400 C. and above, whereby a quite active catalyst can be obtained. When it is desired to produce methane (CH.;) in a great quantity at a high pressure and low temperature or when it is desired to produce hydrogen (H continuously in a great quantity at a high pressure and high temperature, the catalytic metal oxide should be added in a comparatively great quantity, that is, for more than 10% Since such a catalyst can produce a gas composition that has reached equilibrium in accordance with the reaction pressure, reaction temperature, steam-to-carbon ratio, amount of carbon and hydrogen present in the material hydrocarbon, etc., it is possible to change the composition of a gas freely and easily in a wide range in accordance with the requirements.

In case when sulfur compounds are present in a material hydrocarbon a catalyst may be preferably used at a reaction temperature of 750-800 C. which contains an alkali polyaluminate or is prepared by adding at least 1% of alkali polyaluminate, calculated as an alkali metallic oxide, to a refractory carrier, or which is prepared by adding a comparatively small amount, that is, 0.5-2.0%, of chrome oxide or a metallic oxide of Group VIII of the periodic table or a mixture thereof to said catalyst. If such a catalyst is used, catalytic cracking and steam reforming reaction can be proceeded without being poisoned by sulfur. In this case, catalytic cracking may be performed over the former alkali polyaluminate which does not contain any metal in order to produce a gas having a calorific value of more than 6000 Kcal./Nm. For production of a gas having a calorific value of about 4000 KcaL/Nmfi, the latter catalyst containing about 0.5-2.0% of metals is more suitable.

Catalysts can be prepared by any one of the following processes comprising:

(1) Adding a suitable bonding agent to an alkali polyaluminate in powder form and then molding the resulting mixture into tablets, pieces having Rasching ring-like shape or other suitable shapes, or sintering said mixture by firing;

(2) Mixing a refractory carrier material with a finely powdered alkali polyaluminate so as to contain alkali metal in an appropriate quantity and then molding the resulting mixture into a suitable shape by use of a suitable bonding agent, or sintering said mixture by firing;

(3) Adding one member selected from the group of alkali polyaluminates in powdered form to a solution of chrome or a metallic salt of Group VIII of the periodic table to precipitate metals, filtering the resulting slurried mixture, after agitation, with subsequent washing and then molding said mixture into a suitable shape by use of a bonding agent;

(4) Impregnating a sintered alkali polyaluminate or a sintered mixture of an alkali polyaluminate and a refractory carrier material of an appropriate shape into a solution of chrome or a metallic salt of Group VIII of the periodic table and then heating the resulting mixture at a temperature of about 600 C.;

(5) Mixing chrome or a metallic salt of Group VIII of the periodic table with a finely powdered member of the group of alkali polyaluminates or a refractory carrier material containing an appropriate amount of any one of alkali polyaluminates, and then molding the resulting mixture by use of a suitable bonding agent, or sintering said mixture by firing.

Refractory materials which may preferably be used as carriers for the catalyst include, neutral or basic oxides (such as A1 0 Cr O CaO, MgO and the like), or a mixture thereof. As such carriers, there may also be used acidic oxides (such as SiO TiO ZrO and the like) or a mixture thereof, as well as other refractory oxide materials including a mixture of neutral, basic and acidic oxides or a sintered mixture thereof (such as and the like). The alkali polyaluminate, if added in an amount of 1.0% and more, calculated as alkali metal oxide, will be satisfactorily effective in inhibiting the deposition of carbon when a neutral or basic oxide material is used as a carrier, while the alkali polyaluminate will have to be increased in amount in proportion to the amount of acidic oxide when acidic oxide (SiO such as alumina-silicates and the like are included in the carrier. In this connection, the B- or ;3-alkali polyaluminate should preferably be added in an amount at least 2.5 times that of the acidic oxides contained in the catalyst composition in order to obtain the maximum inhibiting effect on the deposition of carbon on the catalyst composition. It is thus advisable that the catalyst composition should contain alkali-richer ;8-alkali polyaluminate if it also contains acidic oxides in an amount of 20% or more (in this case, the amount of the alkali polyaluminate added being at least twice as large as the acidic oxides contained.)

This invention will be better understood by the following examples.

EXAMPLE 1 A potassium polyaluminate (B'-Al O prepared by mixing 6 molecular weight aluminum hydroxide and 1 molecular weight potassium carbonate and then firing the resulting mixture at a temperature of 1400 C., is pulverized, to which CMC solution of 1.8% in concentration is added in the amount of 13%. The mixture thus obtained, after being kneaded, is molded into tablets of 10 mm. in diameter and 7 mm. in height, which is then fired at a temperature of 1500 C. The catalyst thus obtained has the following chemical composition and physical properties.

Shown in the following table are the results of a test 1n RESULTS OF CATALYTIC CRACKING which said catalyst compos1t1on was used in 24-hour continuous catalytic cracking of naphtha, whose boiling point Opemflml range is from 30 C. to 88 C., specific gravity is 0.6455 10 820 1,200 1,440 1,750 (d and sulfur content is 130 p.p.m. hours mus [For the purpose of comparision, the results of a test iml n, 800 796 1 800 7 in which A1 0 was used as a heat medium under the same condition are shown below. Composition of gaseous mixture produced, percent: Chem1cal composition of catalyst (percent) 12-33 -66 1030 99 10-13 10 1% 133 13' zi'ii 2% 2% 1 3i? .1 2; .1 a .1 a .1 1: .121 z Physical properties of catalyst H; Porosity, percent 41.8 3 5: 3; Rate of water so ptio percent 2- A Q; t I d d and 1 205 1 253 1 m 1 268 1565 I mo n o gaspro uce ,m. 7 Bulk denlty Calorific value, Keel/111. 6,230 6,725 6, 855 7,092 71319 Compression strength, kg./cm. 570 v ofsasification. 101 0 n2 5 n4 6 120 1 124 o Abrasion rate, percent 3.5 Damn RESULTS OF CATALYTIC CRACKING Operation 1 hour hours Catalyst of this Heat medium Catalyst of this Heat medium invention A110; invention A110;

Reaction temp., c 750 800 750 800 750 809 750 800 Steam-to-carbon ratio, kgJl 1.616 1.516 1.516 1 516 1 516 1.516 1 516 1 516 Space velocity 1.0 1. 0 1.0 1. 0 1. 0 1. 0 1. 0 1. 0 Composition of gaseous mixture produced, percen 2 c0. 9. 93 12. 12 2.13 1. 07 c0- 1. 10 4.70 1. 41 o. 72 011.. 19. 69 1s. 01 31.53 as. 04 cm. 1. 1. 10 2. 68 3.38 mm 17.82 12. 71 27.10 27. 86 O 2. 77 0.48 6.73 7. 37 n-oinn. 0. 0s 1 0. 23 10.11. 0.26 0.19 iso-O H 0. 24 0. 77 0. 41 11-24211. 0. 11 0. 16 1, a= 0.11. 0. a9 1.18 1. 38 186mm 0. 19 o. as 11.0mm 0. a2 0. 46 H. 40. a2 49. 11 2a. 58 20. 22 N2. 1. 26 0. 20 0. 47 0. 16 o.-- 1 0.12 4 Amount of gas produced, mfl/kl 1, 050 1, 376 618 636 Calorific value, KcaL/m. 6, 916 5, 574 10, 722 11, 258 Efficiency of gasification, percent 98. 3 103. 2 89. 5 81. 2 Carbon deposited/carbon in crude 011, percen 2. 37

In case when a catalyst of the present invention was EXAMPLE 3 used, formation of tar was not noticed at all during operation. On the other hand, when alumina was used as a heat medium, pasty tar was formed in a considerable amount.

EXAMPLE 2 50 parts potassium polyaluminate (fi'-Al O prepared in the same way as Example 1 and 50 parts magnesium oxide (MgO) are mixed, to which CMC solution of 18% in concentration is incorporated in the amountof about 12%. The resulting mixture, after being kneaded, is molded into pieces having Rasching ring-like shape of 20 mm. in outer diameter, 6 mm. in inner diameter and 20 mm. in height, which are then fired at a temperature of 1500 C. The catalyst thus obtained was used in a test wherein the naphtha used in Example 1 was subjected to catalytic cracking for 1750 hours according to the cyclic system comprising 16 minute cycles.

Chemical composition of catalyst (percent) Ig. loss 3.00 SiO 0.07 A1 0 81.77 F3203 CaO 9.11 MgO Tr. Na O 5.05

EXAMPLE 4 The powder of a -A1 0 (K O-5-6Al O prepared by mixing aluminum hydroxide with potassium carbonate at the same ratio and firing the resulting mixture at a temperature of 1380 C. is formed into tablets of 10 mm. in diameter and 6 mm. in height, and is subjected to firing at a temperature of 1500 C. to produce a catalyst. The

chemical composition (percent) of the catalyst thus obtained is as follows.

The naphtha of Example 1 was subjected to catalytic cracking at a space velocity of 5 to 10 by using the catalyst thus obtained, as a result of Which a gas rich in ethylene (C H and having the following composition was produccd.

Chemical composition of catalyst (percent) RESULTS OF CATALYTIC C RACKIN G Reaction temp. C 700 700 750 Space velocity 5 5 Steam-to-carbon ration, kg/l 1. 0 1. 0 1. 0 Composition of gaseous mixture produced,

percent:

ISO-C5H1z. 0. 49 0. 64

n-CsHu. 1. l0 1. 02

Amount of gas produced, mfi/kl 828 701 1, 067

Calorlfie value, KcaL/iu. 12,533 13,218 10,073

Efiiciency oi gasification, percent 122.0 110.0 127. 8

Carbon deposited/carbon in naphtha, percent- 0. 92 1. 10 0. 87

EXAMPLE 5 A crude oil having a specific gravity of 0.858 (15 /4) calorific value of 10,870 Kcal./kg. and containing 86.0% of carbon and 13.5% of hydrogen, was catalytically cracked by using the catalyst of Example 1 according to the cyclic system comprising 10 minute cycles, the result of which are shown below.

RESULTS OF CATALYTIC CRACKING Reaction temp., C 750 800 Steam-to-carbon ratio, kg./i. 1.03 1.03 Space velocity 0.66 0.66 Composition of gaseous mixture produced, pern-C4 io. Other 0| hydrocarbons 2. 39 H1 40. 56 40.08 N. 3. 58 2. 95 0g 0. 45 0. 37 Amount of gas produced, ma /kl. 942 1, 232 Caiorific value, KcaL/mfi- 8, 473 6, 755 Heat produced, J HU/kl- 798 832 Efliciency oi gaslfication, per 74. 5 89. 2

EXAMPLE 6 13-potassium-polyaluminate prepared by mixing aluminum hydroxide with potassium carbonate at the ratio of 3 to 1 and firing the resulting mixture at a temperature of 1400 C. is finely powder and molded into pieces having Rasching ring-like shape of 17 mm. in outer diameter, 5 mm. in inner diameter and 17 mm. in height which are then fired at a temperature of 1500 C. to produce a carrier material. The carrier material is dipped in a solution of nickel nitrate to allow the material to hold therein nickel nitrate in an amount of more than 10%, calculated as NiO, and then fired at a temperature of approximately 500 C. to obtain the catalyst of tipotassium polyaluminate-nickel, having the following chemical composition (percent):

A1 0 81.45 K 8.47 NiO 10.08

8 This catalyst composition was used in a test in which naphtha of specific gravity of 0.6574 (d was subjected to steam reforming at a low temperature and atmospheric pressure, and the test results are shown in the following table from which it is seen that the gas composition al most reached its equilibrium.

EXAMPLE 7 A ,B'-potassium polyaluminate (K O-7.22Al O prepared by mixing potassium carbonate and aluminum hydroxide at the ratio of 1 to 3 and then firing the resulting mixture at a temperature of 1400" C., is added in fine powder form to a mixture of magnesium carbonate and aluminum hydroxide. The thus-obtained mixture, after mixed, is incorporated with a solution of nickel nitrate, agitated and then incorporated with sodium carbonate to precipitate nickel carbonate with the mixture. The slurried mixture so obtained is thoroughly agitated and mixed, filtered and then washed and dried to obtain solid substances which are subsequently fired at a temperature of 400 C. to convert the nickel carbonate therein to nickel oxide. The thus-fired substances are pulverized, blended with alumina cement and molded into pellets which are then heated at a temperature of 250 C. in steam to produce the desired catalyst composition in the pellet form. The chemical composition (percent) of the catalyst composition so produced is compared with that of the conventional commercially available catalyst composition (percent), as shown below.

In the following table, there are shown comparative data obtained at the initial stage of the operation in which these catalyst compositions were used in the continuous steam reforming of naphtha, whose boiling point range is from 40 C. to 170 C., specific gravity is d =0.71, at a pressure of 20 atm. for 24 hours.

Commercially Catalyst of this available catalyst invention Reacti0nten1p.,C 700 750 800 700 750 800 Spaceveiocity(voi./voi.lhr.) 1.0 1.0 1.0 1.0 1.0 1.0 Steam-to-carbon ratio (11:0 moi/C moi) 3.38 3.38 3.38 3.38 3:38 3. 38 Amount of gases produced,

mfl/kl 2,985 3,311 3,585 3,186 3,380 3,720 Elllciency of gasification,

KcaL/Kcal 122 123 128 123 129 Amount of carbon deposited,

percent 2 1. 1 0. 1 0.4 0. 3 tr Composition of gaseous mixture produced (vol.

This catalyst composition of this invention, which was charged into a tubular reactor of 4 inches in inner diameter and 19 feet in length, could be used as such for 4500 hours without lowering its catalytic activity. The used catalyst composition withdrawn from the tubular reactor has the following chemical composition which shows that it extremely slightly decreases in amount of potassium oxide as compared with the conventional ones. In the conventional catalyst, pulverization of catalyst in the lower portion of catalyst zone due to deposition of carbon was noticed in a considerable amount. This phenomenon, however, was not noticed at all in the catalyst of the present invention.

ti-A1 (Na O-IIAI O fused alumina abrasive, is pulverized, formed into pellets and then fired at a temperature of 1400 C. to produce a carrier material. The carrier material is dipped in a nickel nitrate solution the comientration of which is adjusted to allow the carrier material to adsorb the nickel salt in an amount of 5 weight percent calculated as nickel oxide, thereafter withdrawn from the solution and then fired at a temperature of approximately 400 C. thereby removing gaseous nitric acid to pifoduce a desired catalyst composition which has the following chemical composition (percent).

Ignition loss Tr. SiO 0.10 Fegqg A1 03 87.25 CaQ 0.01 MgO Tr. NiO 5.40 Na O 7.21

The catalyst composition showed approximately the same high activity in a laboratory-scale test as that obtained in Example 7, and on the other hand it allowed carbon to deposit thereon in a small amount when put to a prolonged use( about 1000-hour use) in a pilot plantscale test. As is characteristic, however, it could easily be regenerated without damaging it because it was strong in structure and the carbon deposited thereon could readily be blown otf by use of an inert gas such as N gas or the like.

' EXAMPLE 9 fif'-potassium polyaluminate (this being prepared by mixing aluminium hydroxide and potassium carbonate at the ratio of 1:1, firing the resulting mixture at a temperature of 1300" C. to dilfuse a considerable part of the amount of the potassium, and then washing away soluble potassium of free form the fired mixture) is added in fine powder form to a kaolinite clay at the ratio of 1:1. The thus obtained mixture is incorporated with a solution of nickel nitrate and then mixed with each other. The resulting mixture is incorporated with sodium carbonate thereby precipitating nickel carbonate within the mixture. The slurried or pasty mixture so obtained is mixed thoroughly under agitation, thereafter filtered and then washed with water to produce solid substances which are subsequently dried and fired at a temperature of 400 C. to convert the nickel carbonate to nickel oxide. These fired substances 10 are pulverized and formed into pellets having the following chemical composition (percent).

These pellets showed quite the same results as those shown in Example 7 when subjected to the same test as Example 7.

EXAMPLE 10 The catalyst of potassium polyaluminate (5-Al O used in Example 1 is dipped into a solution of cobalt nitrate, incorporated with 1% and 0.5% of C00 and then heated at a temperature of 600 C. to remove nitric gas.

The, catalyst thus obtained was used in the catalytic cracking of the naphtha of Example 1, the results of which are as follows.

porated with porated with Catalyst 1.0% of 00 0.5% of C00 Reaction temp., C 760 800 750 800 Steam-to-carbon ratio, kg./l 1. 01 1. 01 1. 01 1. 01 Space velocity 1. 08 1. 08 1. 08 1. 08 Composition of gaseous mixture produced, percent' Amount of gas produced, ma /kl. 1, 480 2, 185 830 1, 630 Calorific value, KeaL/m. 5, 348 3, 926 9, 825 5, Heatproduced, {I H U/kl 790 857 816 842 Efficiency of gaslfication, perce 100. 2 114 2 110. 0 113. 5

EXAMPLE 1 1 The catalyst of potassium polyaluminate (B'-Al O used in Example 1 is dipped into a solution of chrome nitrate, incorporated with 1.0% of Cr O and then heated at a temperature of 600 C. to remove nitric gas. The catalyst thus obtained was used in catalytic cracking of the gaphtha of Example 1, the results of which are shown e ow.

Reaction temp., C

75 Steam-to-carbon ratio, kg. ll 1. 0i 1. 82 1 Space velocity 1. 08 1. 08 Composition of gaseous mixture produced,

pegzant:

2 9. 25 6. 51 CO 9. 36 20. 50 CH4 ll. 76 7. 53 CzHu 2. 12 1. 06 11. 64 4. 04

a a 3. 39 0. 44: Other 04 hydrocarbons 3. 30 0. 51 H) 49. 20 59. 30 N Am I I ount of gas produced mfi ko. 1, 435 2, Calorific value, Keel/mini. 6,250 a, Heat produced, JHU/kl 897 889 Efificiency of gasification, percent 116 116 What we claim is:

1. A catalyst composition comprising an amount sufficient to inhibit carbon deposition and at least 2% by Weight, calculated as an alkali metal oxide, of at least one alkali polyaluminate selected from the group consisting of B alumina and p" alumina and a refractory catalyst carrier selected from the group consisting of Cr O CaO, MgO, SiO TiO ZrO A1 0 and 2. A catalyst composition comprising:

(a) At least 2% by weight, calculated as alkali metal oxide, of at least one alkali polyaluminate selected from the group consisting of ;3'-alumina and fi"-alumina, and

(b) A different refractory catalyst carrier material.

3. A catalyst composition comprising:

(a) At least 0.5% by weight, calculated as an oxide,

of at least one member selected from the group consisting of chrome oxide and an oxide of a metal of Group VIII of the Periodic Table, and

(b) At least 1% by weight, calculated as an alkali metal oxide, of at least one alkali polyaluminate selected from the group consisting of (3'-alumina and /8"-alumina.

4. The catalyst composition of claim 3 in combination with a different catalyst carrier.

5. A process for producing a catalytic composition comprising:

(a) mixing,

(1) a metal salt solution, said salt selected from a group consisting of chromium salts and salts of a metal of Group VIII of the Periodic Table, with (2) an alkali polyaluminate selected from the group consisting of ,8-alumina and B"-alumina,

(b) filtering the resultant slurry to recover alkali polyaluminate impregnated with said salt solution,

(c) washing the impregnated alkali polyaluminate,

(d) firing the impregnated alkali polyaluminate to a temperature sufficiently high to convert the metal salt to a metal oxide,

(e) regulating the amount and concentration of said salt solution and the amount of said alkali polyaluminate which are mixed so that, after firing, the resultant fired product contains at least 1% by weight, calculated as an alkali metal oxide, of said alkali polyaluminate and at least 0.5% by weight, calculated as an oxide of said metal, and

(11') forming the fired product into a shaped article.

6. The process of claim in which said fired product is formed into a shaped article by mixing said fired product with a bonding agent and molding into the desired shape.

7. The process of claim 5 in which said shaped article is sintered.

8. A process for producing a catalyst composition comprising:

(a) impregnating,

(1) a sintered composition comprising at least 1% by weight of at least one alkali polyaluminate selected from the group consisting of iialumina and /8"-alumina with,

(2) a sulficient amount of a metal salt solution, said metal selected from the group consisting of chromium or a metal of Group VIII of the Periodic Table, so that said composition contains at least 0.5 by weight, calculated as an oxide, of said metal, and

(b) heating the resultant product to a temperature of at least about 600 C.

References Cited UNITED STATES PATENTS 2,454,227 11/1948 Smith 252-434 3,426,066 2/1969 Dombro 260-540 3,291,564 12/1966 Kearby 23 2 2,485,927 10/1949 Schulze 260-669 2,495,278 1/1950 Nickels 260-669 3,271,325 9/1966 Davies 252-466 OTHER REFERENCES On the Structure of Alkali Polyaluminates, Yamaguchi et al., Bulletin of Chem. Soc. of Japan (January 1968).

DANIEL E. WYMAN, Primary Examiner W. J. SHINE, Assistant Examiner US. Cl. X.R. 

